Method and apparatus for forming and processing continuous filaments



April 14, 1970 R. E. SMITH ET AL 3,506,419

METHOD AND APPARATUS FOR FORMING AND PROCESSING CONTINUOUS FILAMENTS Filed Dec. 27, 1966 v 20 W ffi/Z w INVENTORS For 5 $M/7'H 84 LLMl/7'f. 6 455/? WYCZAMM ATTORNEYS United States Patent 3,506,419 METHOD AND APPARATUS FOR FORMING AND PROCESSING CONTINUOUS FILAMENTS Roy E. Smith, Toledo, and Hellmut I. Glaser, Newark,

Ohio, assignors to Owens-Corning Fiberglas Corporation, a corporation of Delaware Filed Dec. 27, 1966, Ser. No. 604,975

Int. Cl. C03c 25/02 US. Cl. 653 12 Claims ABSTRACT OF THE DISCLOSURE The invention relates to a method of and apparatus for processing continuous filaments of glass or other materials and particularly for applying a coating or size to the filaments. The invention embraces a method of and apparatus for orienting filaments attenuated from streams of heat-softened material by a guide surface or member to converge the filaments into a plane and applying a coating or size to the filaments moving in the plane to assure uniform size or coating on all of the filaments.

It has been conventional practice in the formation and processing of continuous filaments particularly continuous textile filaments of glass to attenuate streams of glass to continuous filaments by converging the group of filaments into a strand and winding the strand on a rotating collector to form a package.

In the forming process it is usual to apply lubricant, size or other coating to the filaments to minimize interabrasion and reduce the liability of filament break-outs and enhance the integrity of a strand or linear group formation of the filaments. A conventional means or method of applying a lubricant, size or coating to fibers involves engaging the advancing filaments before convergence is effected with a curved surface bearing a film of the lubricant, size or coating material whereby the lubricant, size or coating material is transferred by wiping action onto the filaments. The curved applicator surface may be a rotating cylindrical roll continuously supplied with a film of the lubricant or coating material, or an endless belt of flexible material supplied continuously with lubricant or coating material engaged by the filaments in advance of a gathering shoe for converging the filaments into a strand.

In forming filaments of streams of glass, it is desirable to attenuate a comparatively large number of streams to fine filaments so as to produce a strand or linear group comprising a corresponding number of filaments. This method of forming continuous filaments involves the use of a glass stream feeder having several rows of orifices in side-by-side relation through which the molten glass is delivered. In a region between the convergence of the filaments into a strand and the stream feeder, the filaments are engaged with the curved surface or cylindrical surface of a size or coating applicator. The filaments from the several rows engage the applicator at different angularities.

The filaments in a row substantially perpendicular engage the applicator surface in substantially a point contact while filaments from other rows engage the applicator surface at varying increased distances, resulling in varying amounts of size or coating on the individual filaments. Due to the difference in angularities of engagement of the filaments with the applicator, the tension in the filaments varies, by reason of the varying tensions in the filaments, and the varying angularities coupled with the tendency for the filaments to adhere to the applicator surface through the adhesive characteristics of "Ice the lubricant, size or coating, the advancing filaments tend to deviate from their normal paths resulting in cross ing of some of the filaments on the applicator surface engendering filament break-outs. With the conventional applicator roll or belt applicator wherein the filaments approach the applicator surface at varying angles and tend to wrap partially around the applicator roll due to the adhesion of the coating material on the applicator, some of the filaments are diverted from their normal paths and periodically, by reason of the tension in the filaments, are snapped back to their normal paths of travel. This action causes a pumping or surging of the cones of glass at the stream feeder which sets up varying tension in the filaments, a further condition fostering filament breakouts.

The present invention embraces a method of guiding a group of filaments attenuated from streams of heatsoftened material to orient the filaments for movement in a plane into contact with a film of lubricant, size or other coating material on an applicator whereby all of the filaments have the same character of engagement with the film so that each filament receives substantially the same amount of lubricant, size or coating material.

Another object of the invention resides in a method of guiding a group of filaments to an applicator for coating the filaments with a lubricant, size or other coating material wherein a uniform minimal area of engagement of each of the filaments with the applicator is attained whereby the tension in all of the filaments is maintained substantially constant thereby minimizing filament breakouts.

Another object of the invention resides in the use of a rotatable guide roll or surface for engaging and orienting the filaments of a group for movement in a common plane whereby all of the filaments move in the same tangential relation with an applicator for transferring coating material onto the filaments wherein the tendency for the filaments to lick or adhere to the applicator surface is greatly reduced and the tendency for the filaments to deviate from their normal paths is substantially eliminated.

Another object of the invention is the provision of means for guiding filaments of a fan or group of filaments attenuated from streams of glass into a predetermined pattern of orientation for effecting transfer of a lubricant, size or coating onto the filaments with a minimum of tension in the filaments whereby the distance from the zone of delivery of the glass streams to the region of convergence of the filaments into a strand may be substantially reduced thereby proportionately reducing air drag on the advancing filaments to further reduce filament tension and foster increased filament attenuating speed.

Another object of the invention resides in the provision of a filament guiding means fashioned of material presenting a minimum of frictional resistance to movement of the filaments and substantially eliminating conditions which would otherwise cause the filaments to move laterally whereby all of the filaments are maintained at substantially the same tension.

Further objects and advantages are within the scope of this invention such as relate to the arrangement, opera tion and function of the related elements of the structure, to various details of construction and to combinations of parts, elements per se, and to economies of manufacture and numerous other features as will be apparent from a consideration of the specification and drawing of a form of the invention, which may be preferred, in which:

FIGURE 1 is a semidiagrammatic view illustrating the method of the invention utilized in conjunction with an applicator for applying a coating material to continuous filaments attenuated from streams of filament-forming material;

FIGURE 2 is a side elevational view of a portion of the arrangement shown in FIGURE 1;

FIGURE 3 is an enlarged fragmentary sectional view illustrating the relationship of the attenuated filaments with one form of guide means and coating applicator;

FIGURE 4 is a view similar to FIGURE 2 illustrating another form of means for guiding a group of filaments to an applicator;

FIGURE 5 is a view similar to FIGURE 4 illustrating a modified form of means for guiding a group of filaments to an applicator, and

FIGURE 6 is an elevational view of a further form of filament guiding means.

Referring to the drawings in detail there is illustrated in FIGURES 1 and 2 a stream feeder or bushing 10 providing a chamber containing heat-softened material such as glass. The stream feeder 10 is fashioned with depending tubular projections 12 providing orifices through which heat-softened filass flows as streams 14, the glass streams at the regions of the projections being in the form of cones. The stream feeder 10 may be provided at its ends with terminal lugs 18 for connection with electric current conductors or bus bars 20 connected with a source of electric current for flowing current through the feeder to maintain the glass in the feeder at a proper viscosity for delivery from the orificed projections.

The stream feeder 10 may be of a character to receive heat-softened glass from a melter (not shown) disposed above the feeder, or the stream feeder may be associated with a forehearth of a glass melting furnace to receive heat-softened glass directly from the forehearth. The streams of glass are attenuated to continuous filaments 22 which are converged into a strand 24 by a gathering member or shoe 25, supported by a member 26. The strand is wound into a package 36, the winding attenuating the streams to fine filaments. The fibers or filaments 22 are attenuated at comparatively high speeds of 10,000 or more lineal feet per minute.

A winding machine of conventional construction is provided with a rotatable mandrel or collet 32 rotated by an electrically energizable motor (not shown) in a conventional manner. A thin walled forming tube or packaging tube 34 is telescoped onto the collet 32 and the strand 24 wound upon the tube 34 to form a strand package 36. A rotatable and a reciprocable oscillator traverse 38 mounted upon a shaft 40 is engaged by the strand, rotation of the oscillator 38 causing individual convolutions of the strand to be in crossing relation as the strand is collected, the traverse oscillator being reciprocated to distribute the strand lengthwise of the package.

Disposed below and adjacent the feeder 10 is a plurality of nozzles 41 for delivering sprays of water onto the the newly formed filaments, the water adhering to the filaments wets the filament guiding means hereinafter described to minimize friction between the rapidly moving filaments and the guide means.

Disposed above and supported by a member 43 adjacent the gathering shoe 25 is an applicator construction 44 mounted upon a support means 45 for effecting transfer of lubricant, size or other coating material onto the individual filaments 22 before they are converged into strand formation. The applicator illustrated is inclusive of a housing or receptacle 46 adapted to contain a lubricant, size or other coating material 47. Journally supported within the receptacle 46 is a roll 48. Mounted forwardly of the front of the receptacle is a nose bar or member 50 which may be stationary or rotatably mounted if desired.

An endless belt 52 of flexible material engages and partially surrounds the roll 48 and member 50. The roll Cir 48 is rotated at a comparatively slow speed by means of an electrically energizable motor 54 or by other suitable motive means. The applicator surface provided by the moving belt 52 acquires a layer or film of the lubricant, size or coating material 47 in the receptacle 46 as the belt moves therethrough. The filaments 22 contact the film of coating material on the surface of the belt 52, and the coating is transferred onto the filaments by wiping action of the filaments with the film.

In prior arrangements the filaments attenuated from rows of glass streams engaged the coating film on an endless belt at different angularities and in varying curved distances depending upon the angles of incidence of the filaments with the curved region of the belt.

Due to the cohesive or tacky characteristics of the lubricant, coating or size and the varying lengths of line contact of the filaments with the applicator surface, the filaments approaching the applicator at substantial angularities tended to move laterally along the applicator surface to an extent that certain of the filaments crossed or overlapped other filaments at the surface causing filament break-outs. Furthermore the differences in the length of line contacts of filaments moving at various angularities established nonuniform tension in the filaments and nonuniform coating on the filaments.

In the arrangement of the present invention, a bracket or bracket means 60 disposed above the region of engagement with the filaments 22 with the endless belt 52 is preferably supported by the housing or receptacle 46. The bracket 60 journally supports a shaft 62 on which is mounted or supported a filament guide means or roll 64. The shaft 62 and the guide roll 64 are adapted to be rotated at a comparatively slow speed by means of an electrically energizable motor 66 supported upon a platform 68 preferably provided as an extension of the bracket means 60. The motor 66 is of a character to rotate the guide roll 64 as low as about one revolution per minute.

As shown in FIGURE 3, the preferred embodiment of the filament guide roll or member 64 is fashioned of graphite and has its peripheral surface area formed with recesses or flutes 72 defining lengthwise arranged lineal ridges or projections 74.

The apices 76 of the projections 74 are adapted to be engaged by the filaments 22. The apices 76 are slightly rounded or curved but are preferably of minimal area to approach insofar as is practicable a point contact with each individual filament so as to reduce friction to a minimum.

As shown in FIGURE 3, the engagement of the filaments with one lineal ridge substantially in a horizontal plane orients the fan or group of filaments in a plane tangent to the curvature of the belt 52 at the nose bar or member 50. Thus, the guide roll 64 orients all of the filaments into a single plane so that all of the filaments have the same short length of contact with the film of coating material on the applicator belt 52. As shown in FIGURES 2 and 3, the filaments 22 attenuated from the left-hand row of streams of glass move in a path to barely engage the filaments of this row with the apex 76 of a lineal ridge 74 on the guide roll 64.

The filaments attenuated from the rows of streams at different distances from the right side of the left-hand row of streams in FIGURE 2 may engage the same projection as those filaments in the left-hand row, or the filaments from the succeeding rows may engage two and perhaps three lineal ridges depending upon the number of rows of streams and the lateral distances between rows of streams. It is desirable that the peripheral distance between adjacent apices 76 of the lineal ridges be spaced sufliciently close so that a minimum number of projections engage the right-hand filaments as viewed in FIGURE 2 so as to reduce friction to a minimum, the spacing to secure these advantages being dependent in a measure upon the exterior diameter of the guide roll 64.

The spacing of the apices 76 may be decreased with a corresponding increase in the number of ridges .74, but in such construction with the apices close together, the right-hand filaments, by reason of their greater angularity may engage three or more projections and thereby increase the frictional resistance to such filaments. If the peripheral spacing of the apices 76 is substantial, then the filaments may only engage one lineal ridge, resulting in an abrupt change of angularity in the right-hand filaments as viewed in FIGURE 2, a condition which tends to promote filament break-outs.

It has been found that a guide roll 64 of a diameter of about one inch at the apices 76 of the lineal ridges 74 and spaced circumferentially about one-sixteenth of an inch is satisfactory to effectively orient the filaments formed from streams from several rows of an average stream feeder in a common plane without encountering a tendency toward filament break-outs. The diameter of the guide roll 64 may be between three-eights of an inch and one and one-quarter inches, and with a smaller diameter roll, the spacing between the lineal ridges should be correspondingly reduced for satisfactory operation.

Another important function is performed by the recesses or flutes between adjacent ridges. As previously mentioned, sprays of water from the nozzles 41 are directed onto the group or fan of filaments 22 providing a moist environment adjacent the guide roll 64, the moisture on the filaments being carried by the filaments into the recesses or flutes 72 so as to maintain the lineal ridges 74 and apices 76 of the graphite roll in wetted condition.

As graphite has a high wetting angle it is found desirable for successful operation to provide the recesses or flutes 72 for maintaining the apices 76 in a wetted condition. While graphite is preferable for the fluted roll 64 because of the comparatively low friction with glass filaments, it is to be understood that other materials may be used as a minimum area of an apex of a lineal ridge in contact with the filaments greatly reduces friction.

Through the use of the fluted guide roll 64, each filament engages the apex 76 of a lineal ridge in substantially a point contact, and the presence of moisture on the apices further reduces friction. Hence, there is no tendency for the filaments to move laterally at their regions of contact with the lineal ridges on the roll 64. The method and arrangement of orienting the filaments of a group in a common plane enables substantially the same tangential engagement of each filament with the curved region of the applicator surface and any tendency for the filaments to lick to or wrap the surface of the applicator is eliminated.

Heretofore it has been a practice to provide a substantial distance of several feet between the glass streams at the feeder and the filament gathering shoe so as to minimize insofar as possible the tendency of wrapping of the filaments with the curved applicator surface.

In the method and arrangement of the present inven' tion, the applicator 44 and the gathering shoe 25 may be disposed at a reduced distance from the streams at the glass feeder as the guide roll 64 effectively orients the group of filaments in a common plane even though the angles of traverse of the filaments between the feeder and the guide roll may be increased by reduction in vertical distance between the glass streams and the applicator. This arrangement has a further advantage in that a fan of filaments of lesser length reduces air drag. The reduction in air drag permits higher filament attenuating speeds because of reduced tension in the filaments. As all of the filaments engage the coating material on the applicator in a uniform manner, each filament acquires substantially the same amount of coating. The filaments are subjected to substantially the same tension and attenuation thereby approved with a minimum of liability break-outs.

While it is found desirable to rotate the fluted guide roll 64 at a comparatively low speed, it is to be understood that the roll may be rotated at a higher speed and attain satisfactory results. The roll 64 is rotatable in order to minimize wear of the surfaces of the apices 76. It is found preferable to rotate the guide roll 64 in a counterclockwise direction as viewed in FIGURES 2 and 3 whereby the apices 76 move in the general direction of linear movement of the filaments.

FIGURE 4 illustrates a modified form of apparatus for performing the method of the invention. The feeder 10 delivers streams 14' of glass from the orificed projections which are attenuated to continuous filaments 22' by winding a strand 24' of the filaments into a package in the manner shown in FIGURE 1. The applicator construction 44' and the gathering shoe 25' are of the same character as hereinbefore described, the applicator construction including a nose bar 50' and an endless belt applicator 52'. A bracket means 80 mounted on the appli cator housing 46' journally supports shafts 82 and 84, the shafts supporting filament guide rolls 86 and 88 preferably of graphite.

The guide rolls 86 and 88 are of the character of the guide-roll 64 shown in FIGURES 1 through 3 having lengthwise flutes providing lineal ridges, the apices of which are engaged by filaments. As shown in FIGURE 4, the axes of the rolls are preferably spaced apart vertically a slight distance so that the apices of the rolls guide the filame'ntsinto a substantially common plane. The rolls 86 and 88 are preferably positioned whereby a vertical median or central plane AA through the feeder 10" is substantially coincident with the apices of the lineal ridges of the rolls at horizontal planes through the axes of the roll supporting shafts 82 and 84.

The rolls 86 and 88 are preferably driven at a slow speed by an electric motor 90 through intermeshing gears (not shown) of conventional construction mounted on the roll supporting shafts 82 and 84.

In the arrangement shown in FIGURE 4, the filaments 22' at the left side of the vertical plane AA are engaged with the apices of the lineal ridges on the guide roll 88, and the filaments 22' at the right side of the plane AA are engaged with the apices of the lineal ridges on the guide roll 86 to converge all of the filaments in a common plane.

In this arrangement the angles of incidence of the filaments with respect to their regions of engagement with the guide rolls are reduced and tension on the filaments is correspondingly reduced and rendered more uniform in all of the filaments. This method of guiding filaments into a common plane is particularly advantageous where the feeder is provided with several hundred orifices delivering a like number of streams for attenuation to filaments necessitating a large number of rows of orifices.

In a feeder construction of this character, the angles of traverse of filaments attenuated from outer rows of streams are substantial and the arrangement of FIGURE 4 is effective in reducing the angles of incidence of the filaments with respect to the regions of engagement with the circumferential zones of the guide rolls. The nose bar 50' is positioned so that the exterior surface zone of the applicator belt is slightly to the left side of the vertical plane AA to assure contact of all of the filaments with the film of lubricant, size or other coating material on the applicator belt.

The arrangement illustrated in FIGURE 5 is generally similar to that shown in FIGURE 4. Mounted on the housing 46" of the applicator construction 44" is a bracket means 80" journally supporting shafts and 102, the shafts carrying guide rolls 104 and 106. In this arrangement the rolls 104 and 106 are preferably fashioned of graphite and are cylindrical providing smooth cylindrical surfaces for engagement with filaments 22" attenuated from glass streams delivered from a feeder such as the feeder 10' shown in FIGURE 4.

Disposed adjacent the rolls 104 and 106 are nozzles 110 for delivering sprays of water directly on the peripheral surfaces of the rolls in order to minimize friction between the roll surfaces and the filaments. The axes of the rolls 104 and 106 are preferably spaced apart vertically a slight distance so that the peripheral surfaces properly guide the filaments into a common plane as in the arrangement illustrated in FIGURE 4. The rolls are arranged whereby a vertical median or central plane A'A' through the feeder is tangent to the cylindrical surfaces of the rolls at the horizontal planes through the axes of the shafts 100' and 102. The rolls may be rotated by contact with the moving filaments or they may be positively rotated by an electric motor 90' through intermeshing gears mounted on the roll supporting shafts 100 and 102. The rolls 104 and 106 may be of diameters in a range of from three-eighths of an inch to one and one-quarter inches.

The nose bar 50" is disposed with respect to the strand 24" and the gathering shoe 25" to assure contact of all of the filaments with the film of coating material on the applicator belt 52". The arrangement illustrated in FIG- URE 4 functions substantially in the manner of the construction of FIGURE 4 and attains the advantages of reducing the angles of incidence of the outer filaments with respect to their zones of contact with the guide rolls and thereby reduces filament tension. By maintaining water on the guide roll surfaces, friction with the glass filaments is held to a minimum.

FIGURE 6 illustrates a modified form of guide roll usable in any of the arrangements hereinbefore described. In this form a shaft 112 supports a guide roll 114 preferably fashioned of graphite. The guide roll 112 is generally of cylindrical shape and is fashioned with lengthwise flutes providing lineal ridges 116 for engagement with filaments for guiding filaments into a common plane. Each of the flutes and lineal ridges is fashioned in a spiral of slight angularity relative to the longitudinal axis of the roll 114. The lineal ridges 116 function in substantially the same manner as the lineal ridges of the guide rolls shown in FIGURES 1 through 4.

It is apparent that, within the scope of the invention, modifications and different arrangements may be made other than as herein disclosed, and the present disclosure is illustrative merely, the invention comprehending all variations thereof.

We claim:

1. A method of establishing a coating of material on each of a plurality of filaments attenuated from heatsoftened glass including advancing a plurality of rows of spaced individual filaments in the general direction of their length by attenuating a strand of the filaments with a rotating member, engaging the advancing filaments with a rotating guide to orient the filaments while in spaced relation in planar fan-shaped formation, converging the filaments into a strand, and engaging the filaments in planar fan-shaped formation with coating material on a rotating applicator to coat each of the filaments in advance of convergence of the filaments into a strand.

2. A method of establishing coating material on each of a plurality of continuous filaments of glass attenuated from streams of heat-softened glass flowing from a plurality of spaced rows of orifices of a stream feeder, continuously rotating a guide surface, engaging each of the filaments with the rotating guide surface to orient the filaments in planar fan-shaped formation, converging the filaments moving away from the guide surface into a strand, applying coating material to each of the filaments at a region of planar orientation of the filaments between the guide surface and the zone of convergence of the filaments into a strand, and winding the strand of filaments on a rotating collector.

3. A method of forming and processing continuous filaments of glass including flowing streams of heat-softened glass from a plurality of substantially parallel rows or orifices of a stream feeder, attenuating the streams to continuous filaments for winding a strand of the filaments on a rotating collector, engaging each of the filaments with a graphite guide to orient the filaments in planar fanshaped formation, continuously rotating the graphite guide, converging the filaments moving away from the guide into a strand, and applying a coating to each of the filaments at a region between the guide and the zone of convergence of the filaments into a strand.

4. Apparatus for coating a plurality of continuous filaments attenuated from streams of glass form a feeder including, in combination, a rotatable collector On which the filaments are wound to attenuate the filaments, support means, rotatable filament guiding means mounted by the support means, said filament guiding means engaging the filaments and orienting the filaments in planar fanshaped orientation, and a rotatable coating applicator engaging each of the filaments in planar fan-shaped orientation for transferring coating material from the applicator onto the filaments, said rotatable filament guiding means being disposed between the feeder and the rotatable applicator.

5. Apparatus for forming and coating filaments of glass including a feeder containing heat-softened glass and having a plurality of orifices through which flow streams of the glass, said streams being attenuated to filaments by winding a strand of the filaments on a rotating collector, support means, an applicator mounted by the support means, a gathering shoe disposed between the applicator and the rotating collector converging the filaments into a strand, a filament guide means disposed between the stream feeder and the applicator, means mounted by the support means journally supportingthe filament guide means for rotation, said filament guide means engaging the filaments to orient the filaments substantially in a plane, means supplying coating material on the applicator, said applicator engaging the filaments at their region of planar orientation to eflect transfer of the coating onto the filaments.

6. The combination of claim 5 wherein the filament guide means includes an elongated member having length wise extending peripheral ridges arranged for engagement with the filaments.

7. The combination according to claim 5 including means for delivering moisture onto the filaments in advance of their engagement with the filament guide means, said guide means including a member of graphite.

8. The combination according to claim 5 wherein the filament guide means includes a member of graphite, and means for rotating said member.

9. The combination according to claim 5 wherein the filament guide means comprises two rotatable members, each of said members being arranged to engage a portion of the total number of filaments.

10. The combination of claim 9 including means for rotating said members.

11. Apparatus for forming and processing continuous filaments of glass including a feeder having a plurality of rows of orifices with the rows arranged in side-by-side relation, said orifices adapted to flow streams of softened glass from the feeder, said streams being attenuated to continuous filaments by winding a strand of the filaments on a rotating collector, a gathering shoe converging the filaments into a strand, support means, rotatable filament guiding means mounted on the support means, means for rotating the filament guiding means, said filament guiding means engaging the individual filaments for orienting the filaments substantially in planar fan-shaped formation, and rotatable applicator means disposed between the filament guiding means and the gathering shoe for applying coating to each of the filaments at the region of planar fan-shaped formation.

12. The combination according to claim 11 wherein the filament guiding means comprises a graphite roll having its periphery fashioned with lengthwise extending flutes.

(References on following page) References Cited UNITED STATES PATENTS FOREIGN PATENTS 1,132,914 3/1957 France.

Fletcher 65--1 S. LEON BASHORE, Primary Examiner Holtschulte 65-1 5 R. L. LINDSAY, 111., Assistant Examiner Theobald 65-- 1 U.S. C1. X.R.

Ewing. 6511; 226193 

